Microsoft Word 02 VF PS1 ISafety doc E6581386 Instruction Manual Variable torque inverter TOSVERTTM VF PS1 200V class 0 4 90kW 400V class 0 75 630kW 1Read first IIIIIntroduction I Safety precautions C[.]
E6581386Ԙ Safety precautions I Introduction II Contents Instruction Manual Variable torque inverter TOSVERT VF-PS1 TOSHIBA TOSHIBA INDUSTRIAL PRODUCTS SALES CORPORATION TOSHIBA INTERNATIONAL CORPORATION PTY., LTD 13131 West Little York RD., Houston, TX 77041, U.S.A TEL: +1-713-466-0277 FAX: +1-713-466-8773 Morton Street Parramatta, NSW2150, Australia TEL: +61-(0)2-9768-6600 FAX: +61-(0)2-9890-7542 TOSHIBA ASIA PACIFIC PTE., LTD 152 Beach Rd., #16-00 Gateway East, Singapore 189721 TEL: +65-6297-0990 FAX: +65-6297-5510 TOSVERTTM VF-PS1 200V class 0.4㨪90kW 400V class 0.75㨪630kW TOSHIBA INFORMATION, INDUSTRIAL AND POWER SYSTEMS TAIWAN CORP 6F, No66, Sec1 Shin Sheng N.RD, Taipei, Taiwan TEL: +886-(0)2-2581-3639 FAX: +886-(0)2-2581-3631 1.Make sure that this instruction manual is delivered to the end user of the inverter unit TOSHIBA CHINA CO., LTD HSBC Tower, 1000 Lujiazui Ring Road, Pudong New Area, Shanghai 200120, The People's Republic of China TEL: +86-(0)21-6841-5666 FAX: +86-(0)21-6841-1161 For further information, please contact your nearest Toshiba Liaison Representative or International Operations - Producer Goods The data given in this manual are subject to change without notice 2009-10 ņķĶĹIJĴĹķ Connection equipment Operations Searching and setting parameters Basic parameters Extended parameters Operation with external signal Monitoring the operation status Measures to satisfy the standards Selection of peripheral devices 10 Table of parameters 11 Specifications 12 Before making a service call 13 Inspection and maintenance 14 Warranty 15 Disposal of the inverter 16 NOTICE Instruction Manual International Operations 9-11, Nihonbashi-honcho 4-chome, Chuo-ku, Tokyo 103-0023, Japan TEL: +81-(0)3-5644-5509 FAX: +81-(0)3-5644-5519 TOSHIBA INTERNATIONAL CORPORATION Variable torque inverter Read first ⢛OO 2.Read this manual before installing or operating the inverter unit, and store it in a safe place for reference E6581386 I I Safety precautions The items described in these instructions and on the inverter itself are very important so that you can use the inverter safely prevent injury to yourself and other people around you as well as prevent damage to property in the area Thoroughly familiarize yourself with the symbols and indications shown below and then continue to read the manual Make sure that you observe all cautions given Explanation of markings Marking Meaning of marking Warning Indicates that errors in operation may lead to death or serious injury Caution Indicates that errors in operation may lead to injury (*1) to people or that these errors may cause damage to physical property (*2) (*1) Such things as injury, burns or shock that will not require hospitalization or long periods of outpatient treatment (*2) Physical property damage refers to wide-ranging damage to assets and materials Meanings of symbols Marking Meaning of marking Indicates prohibition (Don't it) What is prohibited will be described in or near the symbol in either text or picture form Indicates something mandatory (must be done) What is mandatory will be described in or near the symbol in either text or picture form •Indicates warning What is dangerous will be described in or near the symbol in either text or picture form •Indicates caution What the caution should be applied to will be described in or near the symbol in either text or picture form Limits in purpose This inverter is used for controlling speeds of three-phase induction motors in general industrial use Safety precautions ▼The inverter cannot be used in any device that would present danger to the human body or which a malfunction or error in operation would present a direct threat to human life (nuclear power control device, aviation and space flight control device, traffic device, life support or operation system, safety device, etc.) If the inverter is to be used for any special purpose, first get in touch with the supplier ▼When using inverters for critical equipment, even though the inverters are manufactured under strict quality control always fit your equipment with safety devices to prevent serious accident or loss should the inverter fail (such as failure to issue an inverter trouble signal) ▼Do not use the inverter for loads other than those of properly applied three-phase induction motors in general industrial use (Use in other than properly applied three-phase induction motors may cause an accident.) When the inverter is used to control the operation of a permanent magnet motor, a combination test must be conducted in advance For details on the test, contact your supplier E6581386 I General Operation Warning Reference • Never disassemble, modify or repair This can result in electric shock, fire and injury For repairs, call your sales agency • Never remove the front cover when power is on or open door if enclosed in a cabinet The unit contains many high voltage parts and contact with them will result in electric shock • Don't stick your fingers into openings such as cable wiring hole and cooling fan covers This can result in electric shock or other injury • Don't place or insert any kind of object into the inverter (electrical wire cuttings, rods, wires) This can result in electric shock or fire • Do not allow water or any other fluid to come in contact with the inverter This can result in electric shock or fire • Turn power on only after attaching the front cover or closing door if enclosed in a cabinet If power is turned on without the front cover attached or closing door if enclosed in a cabinet, this can result in electric shock or other injury • If the inverter begins to emit smoke or an unusual odor, or unusual sounds, immediately turn power off If the equipment is continued to operate in such a state, the result may be fire Call your local sales agency for repairs • Always turn power off if the inverter is not used for long periods of time since there is a possibility of malfunction caused by leaks, dust and other material The leakage current caused by the contamination may result in fire Disassembly prohibited Prohibited Mandatory Caution • Do not touch any radiating fins or radiating resistors They can become very hot, and you may get burned if you touch them Prohibited contact 2 2 3 Reference E6581386 I Transportation & installation Warning Prohibited Mandatory • Do not install or operate the inverter if it is damaged or any component is missing This can result in electric shock or fire Please consult your local sales agency for repairs • Do not place any inflammable objects nearby If a flame is emitted due to malfunction, it may result in a fire • Do not install in any location where the inverter could come into contact with water or other fluids This can result in electric shock or fire • Must be used in the environmental conditions prescribed in the instruction manual Use under any other conditions may result in malfunction • Must be installed in non-inflammables such as metals The rear panel gets very hot If installation is in an inflammable object, this can result in fire • Do not operate with the front panel cover removed Doing so could result in electric shock • An emergency stop device must be installed that fits with system specifications (e.g shut off input power then engage mechanical brake) Operation cannot be stopped immediately by the inverter alone, thus risking an accident or injury • All options used must be those specified by Toshiba The use of any other option may result in an accident Caution Prohibited • When operating, not hold by the front panel covers The covers may come off and the unit will drop out resulting in injury • Do not install in any area where the unit would be subject to large amounts of vibration That could result in the unit falling, resulting in injury • Do not expose the drive to halogen group disinfectants Failure to comply may cause damage to the electrical components in the drive • Models (20kg or more in weight) designed for 200V-18.5kW or larger and 400V-22kW or larger should be carried by people more, or it could fall and cause an injury • Handle large capacity models using a crane Lifting heavy inverters can cause injury to persons Taking care of safety for users, handle carefully in order not to damage the inverter Carefully lift up the inverter, hanging wires on the hanging bolts or holes on the top or bottom of the inverter Reference 1.4.4 1.4.4 1.4.4 1.4.4 10 1.4.4 1.4.4 Reference 1.4.4 Mandatory Note 1: Always keep the two sling ropes in balance when lifting the inverter, and take care that unexpected force does not apply to the inverter during lifting Note 2: Always protect the inverter with a cover when transporting it Note 3: Do not put your hand in the wiring port or not hold it when transporting the inverter • The main unit must be installed on a base that can bear the unit's weight If the unit is installed on a base that cannot withstand that weight, the unit may fall resulting in injury • Install a mechanical brake whenever the motor requires a brake (device which retains the motor shaft) Failure to so could lead to injury to persons because the inverter itself has no function of mechanically retaining the brake shaft 1.4.4 1.4.4 E6581386 I Wiring Warning Prohibited Mandatory • Do not connect input power to the output (motor side) terminals (U/T1,V/T2,W/T3) That will destroy the inverter and may result in fire • Do not connect resistors to the DC terminals (between PA/+ and PC/-, or between PO and PC/-) That may cause a fire Connect resistors as directed by the instructions for “Installing separate braking resistors.” • Within 15 minutes after turning off input power, not touch wires of devices (MCCB) connected to the input side of the inverter That could result in electric shock • Electrical construction work must be done by a qualified expert Connection of input power by someone who does not have that expert knowledge may result in fire or electric shock • Connect output terminals (motor side) correctly If the phase sequence is incorrect, the motor will operate in reverse and that may result in injury • Wiring must be done after installation If wiring is done prior to installation that may result in injury or electric shock • The following steps must be performed before wiring (1) Turn off all input power to the inverter (2) Wait at least 15 minutes and check to make sure that the charge lamp is no longer lit (3) Use a tester that can measure DC voltage 800VDC or more, and check to make sure that the voltage to the DC main circuits (between PA/+ and PC/-) is 45V or less If these steps are not properly performed, the wiring will cause electric shock • Tighten the screws on the terminal board to specified torque If the screws are not tightened to the specified torque, it may lead to fire • Check to make sure that the input power voltage is +10%, -15% of the rated power voltage written on the rating label (±10% when the load is 100% in continuous operation) If the input power voltage is not +10%, -15% of the rated power voltage (±10% when the load is 100% in continuous operation) this may result in fire • Ground must be connected securely If the ground is not securely connected, it could lead to electric shock or fire when a malfunction or current leak occurs Reference 2.2 2.2 5.19 2.2 2 2 1.4.4 2.2 10 Be Grounded Caution • Do not attach equipment (such as noise filters or surge absorbers) that have built-in capacitors to the output (motor side) terminals That could result in a fire Reference 2.1 Prohibited Caution Caution • Charged capacitors can present a shock hazard even after source power is removed • Drives with EMC filters will retain a charge on the input terminals for up to 15 after the power has been removed To avoid electrical shock, don’t touch the connector terminals and uninsulated source cables at either the main circuit disconnect or the drive until the capacitive charge has dissipated E6581386 I Operations Warning Prohibited Mandatory • Do not touch inverter terminals when electrical power is applied to the inverter even if the motor is stopped Touching the inverter terminals while power is connected to it may result in electric shock • Do not touch switches when hands are wet and not try to clean the inverter with a damp cloth Such practices may result in electric shock • Do not go near the motor in alarm-stop status when the retry function is selected The motor may suddenly restart and that could result in injury Take measures for safety, e.g attaching a cover to the motor, against accidents when the motor unexpectedly restarts • The inverter is tuned automatically (auto-tuning H=, ) when the inverter is started for the first time after setup During auto-tuning, which takes about minutes from several seconds as each model, the motor is energized, although it is standing still The motor may produce noise during auto-tuning, which, however, does not indicate that something is wrong with the inverter or the motor • Do not set the stall prevention level (H) extremely low If the stall prevention level parameter (H) is set at or below the no-load current of the motor, the stall preventive function will always be active and increase the frequency when it judges that regenerative braking is taking place Do not set the stall prevention level parameter (H) below 30% under normal use conditions • Do not turn on the power before attaching the front cover When storing inside the cabinet and using with the front cover removed, always close the cabinet doors first and then turn power on If the power is turned on with the front cover or the cabinet doors open, it may result in electric shock • Make sure that operation signals are off before resetting the inverter after malfunction If the inverter is reset before turning off the operating signal, the motor may restart suddenly causing injury • Provide cranes and hoists with sufficient circuit protection such as mechanical braking Without sufficient circuit protection, the resulting insufficient motor torque during tuning could create a risk of machine stalling/falling Caution Mandatory • Observe all permissible operating ranges of motors and mechanical equipment (Refer to the motor's instruction manual) Not observing these ranges may result in injury Reference 3 6.19 6.26.1 10 6.19 Reference When sequence for restart after a momentary failure is selected Caution Mandatory • Stand clear of motors and mechanical equipment If the motor stops due to a momentary power failure, the equipment will start suddenly when power is restored This could result in unexpected injury • Attach cautions about sudden restart after a momentary power failure on inverters, motors and equipment for prevention of accidents in advance Reference 5.18.1 When retry function is selected Caution Mandatory • Stand clear of motors and equipment If the motor and equipment stop when the alarm is given, selection of the retry function will restart them suddenly after the specified time has elapsed and alarm condition has disappeared This could result in unexpected injury • To prevent accidents, stick caution notices that the inverter has a retry function to the inverter, the motor and the machine Reference 6.15.1 E6581386 I Maintenance and inspection Warning Prohibited Mandatory Reference • Never replace any part by yourself This could be a cause of electric shock, fire and bodily injury To replace parts, call the local sales agency 14.2 • The equipment must be inspected frequently If the equipment is not inspected and maintained, errors and malfunctions may not be discovered which could lead to accidents • Before inspection, perform the following steps (1) Turn off all input power to the inverter (2) Wait at least 15 minutes and check to make sure that the charge lamp is no longer lit (3) Use a tester that can measure DC voltage 800VDC or more, and check to make sure that the voltage to the DC main circuits (between PA/+ and PC/-) is 45V or less If inspection is performed without performing these steps first, it could lead to electric shock 14 14 14.2 Disposal Caution Mandatory Reference • If you throw away the inverter, have it done by a specialist in industry waste disposal* If you throw away the inverter by yourself, this can result in explosion of capacitor or produce noxious gases, resulting in injury (*) Persons who specialize in the processing of waste and known as “industrial waste product collectors and transporters” or “industrial waste disposal persons.” If the collection, transport and disposal of industrial waste is done by someone who is not licensed for that job, it is a punishable violation of the law (Laws in regard to cleaning and processing of waste materials) 16 Attach caution labels Shown here are examples of caution labels to prevent, in advance, accidents in relation to inverters, motors and other equipment If the inverter has been programmed for auto-restart function after momentary power failure or retry function, place caution labels in a place where they can be easily seen and read If the inverter has been programmed for restart sequence of momentary power failure, place caution labels in a place where they can be easily seen and read (Example of caution label) If the retry function has been selected, place caution labels in a location where they can be easily seen and read (Example of caution label) Caution Caution (Functions programmed for restart) (Functions programmed for retry) Do not go near motors and equipment Motors and equipment that have stopped temporarily after momentary power failure will restart suddenly after recovery Do not go near motors and equipment Motors and equipment that have stopped temporarily after an alarm will restart suddenly after the specified time has elapsed and alarm condition has disappeared E6581386 II Introduction Thank you for your purchase of the Toshiba “TOSVERT VF-PS1” industrial inverter This instruction manual is intended for inverters with CPU version 650 or later The CPU version will be frequently upgraded II E6581386 - Contents I Safety precautions ······················································································································································ I I Introduction ······························································································································································· Read first····························································································································································· 1.1 Check the product ········································································································································ 1.2 Contents of the product code ······················································································································· 1.3 Structure of the main body ··························································································································· 1.3.1 Names and functions ···························································································································· 1.3.2 Detaching the cover ······························································································································ 1.3.3 Grounding capacitor switching method ································································································· 1.3.4 Installing the DC reactor························································································································ 1.4 Notes on the application······························································································································· 1.4.1 Motors··················································································································································· 1.4.2 Inverters················································································································································ 1.4.3 What to about the leak current ········································································································· 1.4.4 Installation············································································································································· A-1 A-1 A-1 A-2 A-2 A-10 A-12 A-16 A-17 A-17 A-19 A-20 A-22 Connection equipment ········································································································································ 2.1 Cautions on wiring········································································································································ 2.2 Standard connections··································································································································· 2.3 Description of terminals································································································································ 2.3.1 Main circuit terminals ···························································································································· 2.3.2 Control circuit terminal block················································································································· 2.3.3 RS485 communication connector ········································································································· B-1 B-1 B-3 B-10 B-10 B-11 B-16 Operations··························································································································································· 3.1 Setting/monitor modes ································································································································· 3.2 Simplified operation of the VF-PS1 ·············································································································· 3.2.1 Terminal board operation ······················································································································ 3.2.2 Panel operation····································································································································· C-1 C-2 C-3 C-3 C-7 Searching and setting parameters······················································································································· 4.1 How to set parameters ································································································································· 4.1.1 Setting parameters in the selected quick mode ···················································································· 4.1.2 Setting parameters in the standard setting mode·················································································· 4.2 Functions useful in searching for a parameter or changing a parameter setting ·········································· D-1 D-2 D-2 D-3 D-4 Basic parameters ················································································································································ 5.1 History function ············································································································································ 5.2 Setting acceleration/deceleration time ········································································································· 5.2.1 Automatic acceleration/deceleration ····································································································· 5.2.2 Manually setting acceleration/deceleration time ··················································································· 5.3 Increasing starting torque····························································································································· 5.4 Setting parameters by operating method ····································································································· 5.5 Selection of operation mode ························································································································ 5.6 Selecting control mode································································································································· 5.7 Manual torque boost–increasing torque boost at low speeds ······································································ 5.8 Base frequency ············································································································································ 5.9 Maximum frequency····································································································································· 5.10 Upper limit and lower limit frequencies········································································································· 5.11 Setting frequency command characteristics································································································· 5.12 Preset speed operation (speeds in 15 steps)······························································································· 5.13 Selecting forward and reverse runs (operation panel only) ·········································································· 5.14 Setting the electronic thermal······················································································································· 5.15 Changing the display unit % to A (ampere)/V (volt) ······················································································ 5.16 Meter setting and adjustment······················································································································· E-1 E-1 E-2 E-2 E-3 E-3 E-5 E-6 E-11 E-16 E-16 E-17 E-17 E-18 E-18 E-20 E-21 E-25 E-26 i E6581386 5.17 PWM carrier frequency ································································································································· 5.18 Trip-less intensification ································································································································· 5.18.1 Auto-restart (Restart during coasting)···································································································· 5.18.2 Regenerative power ride-through control/Deceleration stop during power failure·································· 5.19 Dynamic (regenerative) braking - For abrupt motor stop ·············································································· 5.20 Standard default setting ································································································································ 5.21 Searching for all reset parameters and changing their settings ···································································· 5.22 EASY key function ········································································································································ E-30 E-31 E-31 E-32 E-34 E-40 E-42 E-43 Extended parameters··········································································································································· 6.1 Input/output parameters································································································································ 6.1.1 Low-speed signal··································································································································· 6.1.2 Putting out signals of arbitrary frequencies···························································································· 6.2 Input signal selection ···································································································································· 6.2.1 Priority when forward/reverse run commands are entered simultaneously············································ 6.2.2 Assigning priority to the terminal board in the operation panel and operation mode ····························· 6.2.3 Analog input signal switching················································································································· 6.3 Terminal function selection···························································································································· 6.3.1 Keeping an input terminal function always active (ON)·········································································· 6.3.2 Modifying input terminal functions ········································································································· 6.3.3 Modifying output terminal functions ······································································································· 6.4 Basic parameters ······································································································································· 6.4.1 Switching among V/f characteristics and from input terminal··························································· 6.5 V/f 5-point setting·········································································································································· 6.6 Speed command switching ··························································································································· 6.6.1 Using two types of frequency (speed) commands ················································································· 6.7 Operation frequency ····································································································································· 6.7.1 Start frequency/Stop frequency·············································································································· 6.7.2 Run/Stop control with frequency setting signals ···················································································· 6.7.3 Frequency setting signal 0Hz dead zone handling function··································································· 6.8 DC braking···················································································································································· 6.8.1 DC braking············································································································································· 6.8.2 Motor shaft fixing control························································································································ 6.8.3 Function of issuing a 0Hz command during a halt ················································································· 6.9 Auto-stop in case of lower-limit frequency continuous operation (Sleep/Wake-up function) ························· 6.10 Jog run mode················································································································································ 6.11 Setting frequency via external contact input (Up/Down frequency setting) ··················································· 6.12 Jump frequency - jumping resonant frequencies ·························································································· 6.13 Preset speed operation frequencies ············································································································· 6.13.1 Preset speed operation frequency to 15 ····························································································· 6.13.2 Forced oeration control·························································································································· 6.14 Bumpless operation ······································································································································ 6.15 Trip-less intensification ································································································································· 6.15.1 Retry function ········································································································································ 6.15.2 Avoiding overvoltage tripping················································································································· 6.15.3 Output voltage adjustment/Supply voltage correction············································································ 6.15.4 Reverse run prohibition·························································································································· 6.15.5 Output voltage waveform selection········································································································ 6.16 Drooping control ··········································································································································· 6.17 Commercial power/inverter switching ··········································································································· 6.18 PID control ···················································································································································· 6.19 Setting motor constants ································································································································ 6.20 Increasing the motor output torque further in low speed range····································································· 6.21 Torque limit ··················································································································································· 6.22 Current and speed control adjustment ·········································································································· 6.22.1 Current and speed control gain ············································································································· 6.22.2 Prevention of motor current oscillation at light load ··············································································· 6.22.3 Stall prevention control switching··········································································································· F-1 F-1 F-1 F-2 F-3 F-3 F-4 F-5 F-6 F-6 F-6 F-8 F-8 F-8 F-10 F-10 F-10 F-12 F-12 F-12 F-13 F-13 F-13 F-15 F-16 F-17 F-18 F-19 F-21 F-22 F-22 F-22 F-23 F-24 F-24 F-25 F-25 F-27 F-27 F-27 F-29 F-31 F-35 F-39 F-40 F-41 F-41 F-42 F-42 ii ... terminal VFPS1-2004PL~2015PL VFPS1-4007PL~ 4022 PL Shorting-bar M4 screw Grounding capacitor switching switch Grounding terminal (M5 screw) Screw hole for EMC plate VFPS1- 2022 PL, 2037PL VFPS1-4037PL... EMC plate VFPS1-2055PL VFPS1-4055PL, 4075PL Grounding capacitor switching switch Shorting-bar Grounding terminal (M5 screw) Screw hole for EMC plate A-4 M5 screw E6581386 VFPS1-2075PL VFPS1-4110PL... plate VFPS1-2110PM, 2150PM VFPS1-4150PL, 4185PL Grounding capacitor switching switch Shorting-bar M6 screw Grounding terminal (M5 screw) Screw hole for EMC plate VFPS1-2185PM, 2220PM VFPS1-4220PL